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V1 Joe's 2009 F40 SS/TC #470

comegetjoe
I would think Adam wants every chance to have this problem solved correctly. His name is on this kit.

I dont understand what you mean about making the rack the weak point. I can't force the bolts through the holes and there is not enough thread to taper them so they slide through and still be able to torque them down properly. Perhaps a longer bolt with more threads showing, taper them and FORCE them into the hole, torque and the cut off the excess, but then Im putting stress on the rack.

I emailed DF and will give it a day, but I dont understand what they will be able to do from Texas.
 
G
I’m not sure that you have a lot to lose with the BFH or hydraulic options. In my mind the next step would be to cut out that tube and replace with one that has the proper spacing. I think that would be easier than modifying the existing tube by cutting and spacing or cutting out one of mounting points and welding in a new at the correct location.
 
Rttoys
Powder coating could be inside, so I would use a drill bit to remove the coating. This will gain you a little space, but not much. I remember mine was a bit off, but not that much. As stated by someone, the rack could be a tad bent or the bushings worn into a different position too. There’s a bunch of little things that can make it off. I would find a way to put pressure on the bushing and sleeve on the rack, than pushing on the frame. Not sure how p, but that would be my plan. Gotta think about it.
 
comegetjoe
Powder coating could be inside, so I would use a drill bit to remove the coating. This will gain you a little space, but not much. I remember mine was a bit off, but not that much. As stated by someone, the rack could be a tad bent or the bushings worn into a different position too. There’s a bunch of little things that can make it off. I would find a way to put pressure on the bushing and sleeve on the rack, than pushing on the frame. Not sure how p, but that would be my plan. Gotta think about it.


Hmmm. I might understand what the @ah.b.normal was talking about now, you have the same thought as him i beleive. Try another rack.


@Metal Mech and I are gonna try his rack on my frame before we portapower my frame. His bolts up to his frame no problem. If his doesnt fit my frame, then im going to continue spreading my posts apart.
 
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S
I emailed DF and will give it a day, but I dont understand what they will be able to do from Texas.
If you haven't already, measure the center-to-center distance of the tubes, both where the bolt heads are and where the steering rack attaches, and the distance between the holes in the rack itself. That'll tell you if the tubes are just crooked or if they're straight but in the wrong place. Straightening them isn't easy, but it's probably far easier than moving them if they're already straight.

If you want a quicker response from DF you'll have to call them. It's unlikely DF will respond to an email in a day (it'll be more like a week). Whether you call or email, be prepared to tell them the dimensions of the rack and tubes. Hopefully they will tell you what the dimension is supposed to be and be able to recommend a solution.
 
A
Measuring makes sense. Not sure why I didnt think of that avenue when I was knuckle deep in it.
Probably because you were knuckle deep in it. We observers have the advantage of no stress on us, we're not the guy with the troubles. I council patience! Give Adam the chance to give his recommendations. He may have a solution none of us have thought of or considered. This is his creation after all! Maybe using the next size/diameter down in bolts?
 
Ark :D
Joe, did you ever discover if your car is actually tuned beyond the 260 hp stock tune? I'm about to dive into tuning myself, and was surprised to find 3-bar MAP sensors in my car as well.
 
G
I think probably half of the turbo cobalts have the GM upgrade kit that include the 3bar maps. You might want to confirm that someone didn't just add in the sensors without changing the tune, although it probably wouldn't run very well if they didn't at least change the map sensor values (linear/offset). I think the GM upgrade tune is available in the HPT repository. If not, I have a copy.
19369111 GM Performance Power Upgrade Package (crateenginedepot.com)
 
Ark :D
I think probably half of the turbo cobalts have the GM upgrade kit that include the 3bar maps. You might want to confirm that someone didn't just add in the sensors without changing the tune, although it probably wouldn't run very well if they didn't at least change the map sensor values (linear/offset). I think the GM upgrade tune is available in the HPT repository. If not, I have a copy.
19369111 GM Performance Power Upgrade Package (crateenginedepot.com)

Thanks. Once I have the gear, I'll look into it.
 
comegetjoe
Joe, did you ever discover if your car is actually tuned beyond the 260 hp stock tune? I'm about to dive into tuning myself, and was surprised to find 3-bar MAP sensors in my car as well.
Negative. I got the donor to run and drive around the block but never saw enough road to gain butt dyno numbers. Good catch though, youll need those to tune the car!
Having run previous number in a different cobalt of 280whp and 300+tq, im sure i could tell the difference in the way it stood up under load. Wont know for a while yet though.
 
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comegetjoe
Adventurous day today.
Went over to #metalmech's house today to borrow his steering rack to see if it would mate up to my frame, no such luck. His rack has the exact same measurements and is off the exact same amount my rack is off. My frame indeed was welded wrong. I will take no such other answers from anyone stating differently, from DF or anyone otherwise. I am over it and have moved on and I am holding no grudges. Moving on.

I had a buddy come over today and we used a 4ton hydraulic press to spread the two tubes apart while guiding the rack onto the bolts and into place. This worked quite well and only took two minutes. I only wish I had done this weeks ago. We tightened down the nuts and there ya go, one installed steering rack. Got the frame flipped back over and onto jackstands. Ready for the next step.

I picked up a new job a few weeks back and with it being first shift rather than second shift, I have time in the evenings to get a bit more done during the week. Hopefully this trend of progress continues.
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20230826_150147.jpg
20230826_152137.jpg
 
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Desert Sasqwatch
Adversity is the mother of invention! Great work being creative to get your rack mounted in spite of the mount tubes not being positioned correctly. Your not that far from being done, can't wait to see how your Goblin turns out! :D
 
A
Adventurous day today.
Went over to #metalmech's house today to borrow his steering rack to see if it would mate up to my frame, no such luck. His rack has the exact same measurements and is off the exact same amount my rack is off. My frame indeed was welded wrong. I will take no such other answers from anyone stating differently, from DF or anyone otherwise. I am over it and have moved on and I am holding no grudges. Moving on.

I had a buddy come over today and we used a 4ton hydraulic press to spread the two tubes apart while guiding the rack onto the bolts and into place. This worked quite well and only took two minutes. I only wish I had done this weeks ago. We tightened down the nuts and there ya go, one installed steering rack. Got the frame flipped back over and onto jackstands. Ready for the next step.

I picked up a new job a few weeks back and with it being first shift rather than second shift, I have time in the evenings to get a bit more done during the week. Hopefully this trend of progress continues.View attachment 42417View attachment 42418View attachment 42419
Any porta power in a storm!
 
Mahkoi
Is there no use for the factory steering wheel?
I beat it off of the column and saved the airbag for fun times, but anything else?

No uses that for it that I've found. I wondered the same thing and put it under the workbench just in case. It's been there for a long time now.
 
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